Before: 208–218 °F · After: 80–119 °F · Change: ~100 °F cooler
The problem
A thermal scan at a municipal water treatment plant flagged a bolted lug on a chlorine generation reactor reading 208–218 °F. The connection was visibly corroded.
The usual answer to a hot, corroded lug is to replace it. That means parts, a shutdown and labor.
What was done
Instead, the lug was treated in place with Cool-Amp. The surfaces were cleaned to bare metal, and the powder was rubbed on with a damp cloth until the face turned bright silver. The residue was then rinsed off. No part was replaced.
The result
Re-scanned after treatment, the same connection read 80–119 °F, roughly 100 °F cooler than before.
Why it works
Copper grows an oxide film that resists current where surfaces touch, and every bit of extra resistance becomes heat. Cool-Amp replaces the copper at the surface with bonded silver, whose oxide stays thin and conductive. In a bolted busbar test, Cool-Amp joints measured about 23 µΩ (~10%) lower than bare copper.
Extra heat per joint from a 23 µΩ difference: 100 A → 0.2 W · 500 A → 6 W · 1,000 A → 23 W · 2,000 A → 91 W
A field-applied bond also means the fix can be repeated at the next maintenance window, without ordering parts.